Adapter, extension, and connector assemblies for surgical devices

ABSTRACT

An adapter assembly for operably connecting an end effector to a surgical instrument. The adapter assembly includes a first proximal shaft, a second proximal shaft, a first distal shaft, and a second distal shaft. The first proximal shaft includes a first gear assembly. The second proximal shaft defines a longitudinal axis and includes a second gear assembly. The first distal shaft is disposed along the longitudinal axis and includes a third gear assembly. The first gear assembly is mechanically engaged with the third gear assembly. The second distal shaft includes a fourth gear assembly. The second gear assembly is mechanically engaged with the fourth gear assembly. A distal portion of the second distal shaft is disposed at least partially within an internal cavity of the third gear assembly.

BACKGROUND

1. Technical Field

The present disclosure relates to adapter assemblies for use in surgicalsystems. More specifically, the present disclosure relates to adapterassemblies for use with and for electrically and mechanicallyinterconnecting electromechanical surgical devices and surgical loadingunits, and to surgical systems including hand held electromechanicalsurgical devices and adapter assemblies for connecting surgical loadingunits to the hand held electromechanical surgical devices.

2. Background of Related Art

A number of surgical device manufacturers have developed product lineswith proprietary drive systems for operating and/or manipulatingelectromechanical surgical devices. In many instances theelectromechanical surgical devices include a handle assembly, which isreusable, and disposable loading units and/or single use loading unitsor the like that are selectively connected to the handle assembly priorto use and then disconnected from the handle assembly following use inorder to be disposed of or in some instances sterilized for re-use.

In certain instances, an adapter assembly is used to interconnect anelectromechanical surgical device with any one of a number of surgicalloading units to establish a mechanical and/or electrical connectiontherebetween. Due to the complexity of the adapter assembly and theelectromechanical surgical device, it is important to ensure that allelectrical and mechanical connections therebetween can be easily,reliably and repeatedly accomplished.

Accordingly, a need exists for an adapter assembly that provides arobust way of electromechanically interconnecting with the surgicaldevice.

SUMMARY

The present disclosure relates to an adapter assembly for operablyconnecting an end effector to a surgical instrument. The adapterassembly includes a first proximal shaft, a second proximal shaft, afirst distal shaft, and a second distal shaft. The first proximal shaftincludes a first gear assembly. The second proximal shaft defines alongitudinal axis and includes a second gear assembly. The first distalshaft is disposed along the longitudinal axis and includes a third gearassembly. The first gear assembly is mechanically engaged with the thirdgear assembly. Rotation of the first gear assembly causes rotation ofthe third gear assembly. The second distal shaft includes a fourth gearassembly. The second gear assembly is mechanically engaged with thefourth gear assembly. Rotation of the second gear assembly causesrotation of the fourth gear assembly. A distal portion of the seconddistal shaft is disposed at least partially within an internal cavity ofthe third gear assembly.

In disclosed embodiments, the second distal shaft is rotatable about thelongitudinal axis with respect to the third gear assembly.

It is further disclosed that each of the first gear assembly, the secondgear assembly, the third gear assembly, and the fourth gear assembly isdisposed within a housing. Embodiments of the adapter assembly include asupport plate disposed within the housing. The support plate isrotationally fixed with respect to the housing. In embodiments, thesupport plate includes an aperture extending therethrough. A firstaperture of the support plate is disposed about the longitudinal axisand is axially aligned with a portion of the second distal shaft. It isfurther disclosed that the first aperture is axially aligned with aportion of the third gear assembly. It is also disclosed that the secondgear assembly includes a plurality of gear teeth disposed proximally ofthe support plate. In embodiments, the third gear assembly includes aplurality of gear teeth disposed distally of the support plate, and aportion of the first proximal shaft extends through a second aperture ofthe support plate. It is further disclosed that a portion of the seconddistal shaft extends through a third aperture of the support plate.

In disclosed embodiments, the portion of the second distal shaft that isaxially aligned with the first aperture of the support plate includes adiameter that is slightly smaller than a diameter of the first aperturesuch that the second distal shaft is rotatable with respect to thesupport plate and such that the support plate supports the second distalshaft.

It is further disclosed that the adapter includes a first assemblyoperably connected to the first distal shaft for converting rotationalmotion from the first distal shaft to longitudinal movement to perform afirst function (e.g., axially moving a trocar member with respect to thefirst distal shaft). Additionally, it is disclosed that the adapterincludes a second assembly operably connected to the second distal shaftfor converting rotational motion from the second distal shaft tolongitudinal movement to perform a second function (e.g., axially movingan anvil with respect to the second distal shaft).

The present disclosure also relates to a surgical instrument including afirst proximal shaft, a second proximal shaft, a first distal shaft, anda second distal shaft. The first proximal shaft is disposed inmechanical cooperation with a first gear assembly. The second proximalshaft defines a longitudinal axis and is disposed in mechanicalcooperation with a second gear assembly. The second gear assembly isrotatable about the longitudinal axis with respect to the first proximalshaft. The first distal shaft is along the longitudinal axis and isdisposed in mechanical cooperation with a third gear assembly. The thirdgear assembly is rotatable about the longitudinal axis with respect tothe first proximal shaft. The first gear assembly is mechanicallyengaged with the third gear assembly such that rotation of the firstgear assembly causes rotation of the third gear assembly. The seconddistal shaft includes a fourth gear assembly. The second gear assemblyis disposed in mechanical cooperation with the fourth gear assembly suchthat rotation of the second gear assembly causes rotation of the fourthgear assembly. A distal portion of the second distal shaft is disposedat least partially within an internal cavity of the third gear assembly.

In disclosed embodiments, the second proximal shaft is rotatable withrespect to the third gear assembly.

It is further disclosed that the surgical instrument includes a firstassembly operably connected to the first distal shaft for convertingrotational motion from the first distal shaft to axially move a trocarmember with respect to the first distal shaft. It is also disclosed thatthe surgical instrument includes second assembly operably connected tothe second distal shaft for converting rotational motion from the seconddistal shaft axially move an anvil with respect to the second distalshaft.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present disclosure are described herein withreference to the accompanying drawings, wherein:

FIG. 1 is a perspective separated view of an adapter assembly, inaccordance with an embodiment of the present disclosure, an extensionassembly, in accordance with an embodiment of the present disclosure,and an exemplary handheld electromechanical surgical device;

FIG. 2 is a perspective side view of the exemplary handheldelectromechanical surgical device of FIG. 1;

FIG. 3 is a perspective side view of the adapter assembly of FIG. 1;

FIG. 4 is a perspective side view of the adapter assembly of FIG. 3 withthe outer sleeve removed;

FIG. 5 is a perspective side view of the adapter assembly of FIGS. 3 and4 with proximal and distal housings of first and second pusherassemblies removed;

FIG. 6 is a cross-sectional side view of the adapter assembly of FIGS.2-4 taken along line 6-6 in FIG. 3;

FIG. 7 is a cross-sectional side view of the adapter assembly of FIGS.2-5 taken along line 7-7 in FIG. 5;

FIG. 8 is an enlarged, perspective view of a coupling assembly and atransfer assembly of the adapter assembly of FIGS. 2-7;

FIG. 9 is a perspective side view of the adapter assembly of FIGS. 2-7with the housing assemblies removed;

FIG. 10 is an enlarged view of the indicated area of detail of FIG. 9;

FIG. 11 is an enlarged view of the indicated area of detail of FIG. 6;

FIG. 12 is an enlarged view of the indicated area of detail of FIG. 7;

FIG. 13 is a perspective end view of the transfer assembly of FIG. 8;

FIG. 14 is an enlarged view of the indicated area of detail of FIG. 6;

FIG. 15 is an enlarged view of the indicated area of detail of FIG. 7;

FIG. 16 is an enlarged view of the indicated area of detail of FIG. 9;

FIG. 17 is a perspective side view of the extension assembly of FIG. 1;

FIG. 18 is a perspective side view of an inner flexible band assembly ofthe extension assembly of FIG. 17;

FIG. 19 is a perspective side view of an outer flexible band assembly ofthe extension assembly of FIG. 17;

FIG. 20 is a perspective side view of the inner and outer flexible bandassemblies of FIGS. 18 and 19 and an exploded view of a frame assemblyof the extension assembly of FIG. 17;

FIG. 21 is a perspective side view of the inner and outer flexible bandassemblies and the frame assembly of FIG. 20;

FIG. 22 is an enlarged view of the indicated area of detail of FIG. 21;

FIG. 23 is a front, perspective view of the inner and outer flexibleband assemblies and the frame assembly of FIG. 20;

FIG. 24 is an enlarged view of the indicated area of detail of FIG. 23;

FIG. 25 is a cross-sectional end view taken along line 25-25 of FIG. 17;

FIG. 26 is a cross-sectional end view taken along line 26-26 of FIG. 17;

FIG. 27 is an enlarged perspective side view of a distal end of theinner and outer flexible band assemblies and the frame assembly of FIG.20 including a proximal seal member and first and second distal sealmembers;

FIG. 28 is an exploded perspective view of the proximal seal member andfirst and second distal seal members of FIG. 27;

FIG. 29 is an exploded view of a trocar assembly of the extensionassembly of FIG. 17;

FIG. 30 is a perspective side view of the trocar assembly of FIG. 29;

FIG. 31 is a cross-sectional side view taken along line 31-31 of FIG.30;

FIG. 32 is a cross-sectional top view taken along line 32-32 of FIG. 17;

FIG. 33 is an enlarge cross-sectional view of the distal end of theextension assembly of FIG. 17;

FIG. 34 is a perspective side view of the adapter assembly of FIG. 3connected to the extension assembly of FIG. 17 and an end effector andan anvil assembly connected to the extension assembly;

FIG. 35 is an enlarged cross-sectional side view of the indicated areaof detail of FIG. 34;

FIG. 36 is a rear, perspective view of an adapter assembly according toanother embodiment of the present disclosure;

FIG. 37 is a perspective side view of the adapter assembly of FIG. 36with an outer sleeve and a handle member removed;

FIG. 38 is a perspective side view of the adapter assembly of FIG. 37with a base and a housing member removed;

FIG. 39 is a perspective side view of the adapter assembly of FIG. 38with a support structure removed;

FIG. 40 is a cross-sectional side view taken along line 40-40 of FIG.36;

FIG. 41 is a cross-sectional side view taken along line 41-41 of FIG.40;

FIG. 42 is a rear, perspective view of an adapter assembly according toyet another embodiment of the present disclosure;

FIG. 43 is a cross-sectional side view taken along line 43-43 of FIG.42;

FIG. 44 is a cross-sectional side view taken along line 44-44 of FIG.42;

FIG. 45 is a perspective view of a connector assembly according to anembodiment of the present disclosure;

FIG. 46 is an exploded perspective view of the connector assembly ofFIG. 45;

FIG. 47 is a perspective view of the connector assembly of FIG. 45 witha sleeve and first section of a tubular extension removed;

FIG. 48 is a perspective view of the connector assembly of FIG. 45 withthe sleeve removed;

FIG. 49 is a cross-sectional side view taken along line 49-49 of FIG.45;

FIG. 50 is a perspective view, with parts separated, of a distal end ofthe adapter assembly of FIG. 1 in accordance with embodiments of thepresent disclosure;

FIG. 51 is a transverse cross-sectional view of a portion of the distalend of the adapter assembly of FIG. 50;

FIG. 52 is a longitudinal cross-sectional view of the distal end of theadapter assembly taken along line 52-52 of FIG. 50;

FIGS. 53 and 54 are perspective views of a distal portion of the adapterassembly of FIG. 50, with some parts removed;

FIG. 55 is a perspective view of a sensor assembly of the adapterassembly of FIG. 50;

FIGS. 56 and 57 are perspective views of an alternate embodiment of aportion of a drive shaft assembly engaged with a support plate;

FIG. 58 is a perspective assembly view of the portion of the drive shaftassembly and the support plate of FIGS. 56 and 57;

FIG. 59 is a perspective view of a distal gear of the drive shaftassembly of FIGS. 56-58;

FIG. 60 is a cross-sectional view of the drive shaft assembly andsupport plate taken along line 60-60 in FIG. 57; and

FIG. 61 is a partial cross-sectional view of the drive shaft assemblyand support plate taken along line 61-61 in FIG. 60.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments of the presently disclosed adapter assemblies and extensionassemblies for surgical devices and/or handle assemblies are describedin detail with reference to the drawings, in which like referencenumerals designate identical or corresponding elements in each of theseveral views. As used herein the term “distal” refers to that portionof the adapter assembly or surgical device, or component thereof,farther from the user, while the term “proximal” refers to that portionof the adapter assembly or surgical device, or component thereof, closerto the user.

With reference to FIG. 1, an adapter assembly in accordance with anembodiment of the present disclosure, shown generally as adapterassembly 100, and an extension assembly according to an embodiment ofthe present disclosure, shown generally as extension assembly 200, areconfigured for selective connection to a powered handheldelectromechanical instrument shown, generally as surgical device 10. Asillustrated in FIG. 1, surgical device 10 is configured for selectiveconnection with adapter assembly 100, and, in turn, adapter assembly 100is configured for selective connection with an extension assembly 200.Extension assembly 200 is configured for selective connection with atool assembly or end effector, e.g. tool assembly 30 (FIG. 34),including a loading unit, e.g. loading unit 40 (FIG. 34), and an anvilassembly, e.g., anvil assembly 50 (FIG. 34), for applying a circulararray of staples (not shown) to tissue (not shown).

As illustrated in FIGS. 1 and 2, surgical device 10 includes a handlehousing 12 having a lower housing portion 14, an intermediate housingportion 16 extending from and/or supported on lower housing portion 14,and an upper housing portion 18 extending from and/or supported onintermediate housing portion 16. A distal half-section of upper housingportion 18 defines a nose or connecting portion 18 a configured toaccept a corresponding drive coupling assembly 110 (FIG. 10) of adapterassembly 100. For a detailed description of the structure and functionof an exemplary electromechanical instrument, please refer to commonlyowned U.S. Pat. Appl. Publ. No. 2012/0253329 (“the '329 application”),the contents of which is incorporated by reference herein in itsentirety.

Adapter assembly 100 will now be described with reference to FIGS. 3-20.Referring initially to FIG. 3, adapter assembly 100 includes a proximalend 102 configured for operable connection to connecting portion 18 a(FIG. 1) of surgical device 10 (FIG. 1) and a distal end 104 configuredfor operable connection to extension assembly 200 (FIG. 1). Inaccordance with the present disclosure, adapter assembly 100 may besubstantially or fully rigid along the entire length.

Turning to FIGS. 3-5, from proximal end 102 to distal end 104 of adapterassembly 100, adapter assembly 100 includes a drive coupling assembly110, a drive transfer assembly 130 operably connected to drive couplingassembly 110, a first pusher assembly 160 operably connected to drivetransfer assembly 130, and a second pusher assembly 180 operablyconnected to drive transfer assembly 130. Each of drive transferassembly 130, first pusher assembly 160 and second pusher assembly 180are operably maintained within an outer sleeve 106 (FIG. 3). As will bedescribed in further detail below, a shaft 108 (FIG. 3) extendslongitudinally through adapter assembly 100 and is operably connected todrive transfer assembly 130.

With reference to FIGS. 5-9, drive coupling assembly 110 has acylindrical profile and is configured to selectively secure adapterassembly 100 to surgical device 10 (FIG. 1). Drive coupling assembly 110includes a connector housing 112 and a connector extension 114 fixedlyconnected to connector housing 112 by a mounting plate 113. Connectorhousing 112 and connector extension 114 operate to rotatably support afirst rotatable proximal drive shaft 116, a second rotatable proximaldrive shaft 118, and a third rotatable proximal drive shaft 120.Connector housing 112 and connector extension 114 of drive couplingassembly 110 also rotatably supports first, second, and third connectorsleeves 122, 124, and 126, respectively. Each of connector sleeves 122,124, 126 is configured to mate with respective first, second, and thirddrive connectors (not shown) of surgical device 10 (FIG. 1). Eachconnector sleeve 122, 124, 126 is further configured to mate with aproximal end 116 a, 118 a, 120 a of respective first, second and thirdproximal drive shafts 116, 118, 120.

Drive coupling assembly 110 also includes first, second and thirdbiasing members 122 a, 124 a and 126 a disposed distally of respectivefirst, second and third connector sleeves 122, 124, 126. Each of biasingmembers 122 a, 124 a and 126 a is disposed about respective first,second, and third rotatable proximal drive shafts 122, 124 and 126 tohelp maintain connector sleeves 122, 124, and 126 engaged with thedistal end of respective drive rotatable drive connectors (not shown) ofsurgical device 10 when adapter assembly 100 is connect to surgicaldevice 10. In particular, first, second and third biasing members 122 a,124 a and 126 a function to bias respective connector sleeves 122, 124and 126 in a proximal direction.

For a detailed description of an exemplary drive coupling assembly,please refer to the '329 application, the contents of which waspreviously incorporated by reference herein.

With reference to FIGS. 9-13, drive transfer assembly 130 (FIGS. 10 and13) of adapter assembly 100 has a cylindrical profile and operablyconnects distal ends of first, second and third rotatable proximal driveshafts 116, 118 and 120 to shaft 108, first pusher assembly 160, andsecond pusher assembly 180, respectively. Drive transfer assembly 130includes a support plate 132 (FIGS. 11 and 12) secured to a proximal endof connector housing 112 and a drive transfer housing 134 positionedadjacent support plate 132. Support plate 132 and housing 134 operate torotatably support a first rotatable distal drive shaft 136, a secondrotatable distal drive shaft 138 and a drive member 140.

First and second rotatable distal drive shafts 136 and 138 are eachoperably connected to respective first and second rotatable proximaldrive shafts 116 and 118 of drive coupling assembly 110 by a pair ofgears. In particular, distal ends of each of first and second rotatableproximal drive shaft 116 and 118 include a geared portion 142 a and 144a, respectively, which engages a gear assembly or proximal drive gear142 b and 144 b on a proximal end of respective first and second distaldrive shafts 136 and 138. As shown, each of respective paired gearedportion and proximal drive gear 142 a, 142 b and 144 a, 144 b are thesame size to provide a 1:1 gear ratio between the respective rotatableproximal and distal drive shafts. In this manner, respective rotatableproximal and distal drive shafts rotate at the same speed. However, itis envisioned that either or both of the paired geared portions andproximal drive gears may be of different sizes to alter the gear ratiobetween the rotatable proximal and distal drive shafts.

A distal end of third proximal drive shaft 120 of drive couplingassembly 110 includes a geared assembly or gear portion 146 a thatengages a geared assembly or gear portion 146 b formed on a proximal endof drive member 140 of drive transfer assembly 130. The size of gearedportion 146 a on third proximal drive shaft 120 and geared portion 146 bon drive member 140 are the same size to provide a 1:1 gear ratiobetween third proximal drive shaft 120 and drive member 140. In thismanner, third proximal drive shaft 120 and drive member 140 rotate atthe same speed. However, it is envisioned that either or both of gearedportions 146 a, 146 b may be of different sizes to alter the gear ratiobetween third proximal drive shaft 120 and drive member 140. A distalend of drive member 140 defines a socket 145 that receives a proximalend 108 a of shaft 108. Alternatively, socket 145 may be configured tooperably engage a proximal end 208 a of a drive shaft (FIG. 17) of anextension assembly 200 (FIG. 17).

Drive transfer assembly 130 also includes a drive connector 148 (FIG.11) operably connecting first rotatable distal drive shaft 136 to firstpusher assembly 160 and a tubular connector 150 operably connectingsecond rotatable distal drive shaft 138 to second pusher assembly 180.In particular, a distal end of first rotatable distal drive shaft 136includes a geared portion 152 a that engages a geared portion 152 b ofdrive connector 148. A distal end of second rotatable distal drive shaft138 includes a geared portion 154 a that engages a drive gear 154 bsecured to a distal end of tubular connector 150.

As shown in FIG. 10, geared portion 152 a of first rotatable distaldrive shaft 136 is smaller than geared portion 152 b of drive connector148 to provide a gear ratio of greater than 1:1 between first rotatabledistal drive shaft 136 and drive connector 148. In this manner, driveconnector 148 rotates at a slower speed than first rotatable distaldrive shaft 136. Similarly, geared portion 154 a of second rotatabledistal drive shaft 138 is smaller than drive gear 154 b on tubularconnector 150 to provide a gear ratio of greater than 1:1 between secondrotatable distal drive shaft 138 and drive connector 148. In thismanner, tubular connector 150 rotates at a slower speed than secondrotatable distal drive shaft 138. However, it is envisioned that each ofpaired geared portion 152 a and geared portion 152 b, and geared portion154 a and drive gear 154 b may be the same size to provide a gear ratioof 1:1 between respective first rotatable distal drive shaft 136 anddrive connector 148 and between second rotatable distal drive shaft 138and tubular connector 150.

With additional reference to FIGS. 56-61, a drive shaft assembly 590including an alternate embodiment of a proximal drive shaft 600, asupport plate 640, and a gear assembly or distal gear 680 is shown.Proximal drive shaft 600 includes a pilot shaft 610 and a gear assemblyor geared portion 620. Support plate 640 includes a plurality ofapertures 642 extending therethrough. In particular, support plate 640includes a first aperture 642 a, a second aperture 642 b, and a thirdaperture 642 c (see FIG. 58). Distal gear 680 includes a proximalportion 682, a geared portion 684, a distal portion 686, and an internalcavity 688.

Proximal portion 682 of distal gear 680 extends at least partiallythrough and is supported by walls 643 a (FIG. 58) of first aperture 642a of support plate 640. Moreover, an outer diameter “od” (FIG. 59) ofproximal portion 682 is slightly smaller than a diameter “dfo” (FIG. 58)of first aperture 642 a such that proximal portion 682 is rotatablysupported within first aperture 642 a (FIGS. 60 and 61).

A distal portion 612 (FIG. 58) of pilot shaft 610 of proximal driveshaft 600 extends at least partially through internal cavity 688 ofdistal gear 680. The diameters of distal portion 612 of pilot shaft 610and internal cavity 688 are configured to allow pilot shaft 610 torotate with respect to internal cavity 688. Moreover, proximal driveshaft 600 is thus able to rotate with respect to distal gear 680.Further, proximal drive shaft 600 is also supported by support plate640. Additionally, proximal drive shaft 600 and distal gear 680 are bothrotatable about a common axis, i.e., longitudinal axis “Z” (FIG. 61).

While not explicitly shown in FIGS. 56-61, support plate 640 issupported within and/or secured to a proximal end of connector housing112 in a similar fashion to support plate 132, discussed above (FIGS. 11and 12, for example).

With particular reference to FIG. 60, geared portion 620 of proximaldrive shaft 600 engages proximal drive gear 142 b on the proximal end offirst distal drive shaft 136. Accordingly, rotation of proximal driveshaft 600 causes rotation of first distal drive shaft 136. Further, asdiscussed in further detail herein, rotation of first distal drive shaft136 drives a function (e.g., clamping tissue) of the end effector 30.

Additionally, geared portion 146 a of third proximal drive shaft 120engages geared portion 684 of distal gear 680. Accordingly, rotation ofthird proximal drive shaft 120 causes rotation of distal gear 680.Further, and with particular reference to FIG. 60, distal portion 686 ofdistal gear 680 forms a U-shaped receptacle or socket configured toreceive or engage proximal end 108 a of shaft 108. As discussed infurther detail herein, rotation of shaft 108 drives a function (e.g.,axially moving trocar member 274) of the end effector 30.

It is envisioned that geared portion 620 of proximal drive shaft 600includes between about 10 teeth and about 15 teeth. In particularembodiments, geared portion 620 of proximal drive shaft 600 includes 13teeth. It is envisioned that geared portion 684 of distal gear 680includes between about 25 teeth and about 35 teeth. In particularembodiments, geared portion 684 of distal gear 680 includes 30 teeth. Itis further disclosed that geared portions 620 and 684 may include moreor fewer teeth than the particular amounts discussed.

It is also disclosed that proximal drive shaft 600 and distal gear 680are rotatable in different directions from each other, at the same time.That is, it is envisioned that while proximal drive shaft 600 rotatesclockwise, distal gear 680 rotates counter-clockwise. It is furtherenvisioned that proximal drive shaft 600 and distal gear 680 rotate inthe same direction as each other, at the same time. Such rotations areenabled at least because proximal drive shaft 600 and distal gear 680rotate about the same axis, and they are rotatable with respect to oneanother, as discussed above.

With particular reference to FIGS. 58 and 60, support plate 640 isshown. Support plate 640 includes a plurality of apertures 642 andnotches 644 extending therethrough. As shown in FIGS. 60 and 61, distalportion 612 of pilot shaft 610 and proximal portion 682 of distal gear680 extend through, are supported by, and are rotatable with respect tofirst aperture 642 a. Further, pilot shaft 610, distal gear 680, andfirst aperture 642 a are coaxial. Additionally, it is envisioned that aportion of third proximal drive shaft 120 extends through, is supportedby, and is rotatable with respect to second aperture 642 b (FIG. 60). Inthese embodiments, third proximal drive shaft 120, geared portion 146 aof third proximal drive shaft 120, and second aperture 642 b arecoaxial. It is further envisioned that a portion of first distal driveshaft 136 extends through, is supported by, and is rotatable withrespect to third aperture 642 c (FIG. 60). Here, first distal driveshaft 136, proximal drive gear 142 b, and third aperture 642 c arecoaxial. Additionally, the amount, size, shape, and positioning ofapertures 642 and notches 644 can be manufactured to suit a particularpurpose.

Referring now to FIGS. 9-13, first pusher assembly 160 includes proximaland distal housing sections 162, 164 (FIG. 11), a planetary gearassembly 166 operably mounted within proximal housing section 162, ascrew member 168 (FIG. 11) operably connected to planetary gear assembly166 and rotatably supported within distal housing section 164, and apusher member 170 (FIG. 11) operably connected to screw member 168 andslidably disposed within distal housing section 164. Planetary gearassembly 166 includes first and second planetary gear systems 166 a, 166b (FIG. 10). First planetary gear system 166 a includes a central drivegear 172 a mounted on a distal end of drive connector 148 of drivetransfer assembly 130 and a plurality of planetary gears 174 a rotatablymounted to a rotatable support ring 176.

Each planetary gear 174 a of first planetary gear system 166 a engagescentral drive gear 172 a and a toothed inner surface 165 of proximalhousing section 162. As central drive gear 172 a rotates in a firstdirection, i.e., clockwise, each planetary gear 174 a rotates in asecond direction, i.e., counter-clockwise. As each planetary gear 174 arotates in the second direction, engagement of planetary gears 174 awith toothed inner surface 165 of distal housing section 162 causesrotatable support ring 176 to rotate in the first direction. Conversely,rotation of central drive gear 172 a in the second direction causesrotation of each planetary gear 174 a in the first direction therebycausing rotation of rotatable support ring 176 in the second direction.The configuration of first planetary gear system 166 a provides areduction in the gear ratio. In this manner, the speed of rotation ofrotatable support ring 174 is less than the speed of rotation of centraldrive gear 170 a.

Second planetary gear system 166 b includes a central drive gear 172 bsecurely affixed to rotatable support ring 176 and a plurality ofplanetary gears 174 b rotatably mounted to a proximal end surface 168 aof screw member 168. Each planetary gear 174 b of second planetary gearsystem 166 b engages central drive gear 172 b and toothed inner surface165 of proximal housing section 162. As rotatable support ring 176 offirst planetary gear system 166 a rotates in the first direction therebycausing central drive gear 172 b to also rotate in the first direction,each planetary gear 174 b rotates in the second direction. As eachplanetary gear 174 b rotates in the second direction, engagement ofplanetary gears 174 b with toothed inner surface 165 of proximal housingsection 162 causes screw member 168 to rotate in the first direction.Conversely, rotation of central drive gear 172 b in the second directioncauses rotation of each planetary gear 174 b in the first direction,thereby causing screw member 168 to rotate in the second direction. Theconfiguration of second planetary gear system 166 b provides a reductionin the gear ratio. In this manner, the speed of rotation of screw member168 is less than the speed of rotation of central drive gear 172 b.First and second planetary gear systems 166 a, 166 b operate in unisonto provide a reduction in the gear ratio between first rotatableproximal drive shaft 116 and screw member 168. In this manner, thereduction in the speed of rotation of screw member 168 relative to driveconnector 148 is a product of the reduction provided by the first andsecond planetary gear systems 166 a, 166 b.

Screw member 168 is rotatably supported within proximal housing portion162 and includes a threaded distal end 168 b that operably engages athreaded inner surface 170 a of pusher member 170. As screw member 168is rotated in the first direction, engagement of threaded distal end 168b of screw member 168 with threaded inner surface 170 a of pusher member170 (which is keyed to permit axial translation and prevent rotationthereof) causes longitudinal advancement of pusher member 170, asindicated by arrows “A” in FIG. 12. Conversely, rotation of screw member168 in the second direction causes retraction of pusher member 170.

Pusher member 170 of first pusher assembly 160 of adapter assembly 100includes a pair of tabs 178 formed on a distal end thereof for engagingconnector extensions 240, 242 (FIG. 19) of outer flexible band assembly230 (FIG. 19) of extension assembly 200 (FIG. 17). Although shown astabs 178, it is envisioned that pusher member 170 may include anystructure suitable for selectively engaging connector extensions 240,242 of outer flexible band 230 of extension assembly 200.

With particular reference now to FIGS. 14-16, second pusher assembly 180is substantially similar to first pusher assembly 160, and includesproximal and distal housing sections 182, 184, a planetary gear assembly186 operably mounted within proximal housing section 182, a screw member188 operably connected to planetary gear assembly 186 and rotatablysupported within distal housing section 184, and a pusher member 190operably connected to screw member 188 and slidably disposed withindistal housing section 184. Planetary gear assembly 186 includes firstand second planetary gear systems 186 a, 186 b (FIG. 16). Firstplanetary gear system 186 a includes a central drive gear 192 a mountedon a distal end of tubular connector 150 of drive transfer assembly 130and a plurality of planetary gears 194 a rotatably mounted to arotatable support ring 196.

Each planetary gear 194 a of first planetary gear system 186 a engagescentral drive gear 192 a and a toothed inner surface 185 of proximalhousing section 182. As central drive gear 192 a rotates in a firstdirection, i.e., clockwise, each planetary gear 194 a rotates in asecond direction, i.e., counter-clockwise. As each planetary gear 194 arotates in the second direction, engagement of planetary gears 194 awith toothed inner surface 185 of distal housing section 182 causesrotatable support ring 196 to rotate in the first direction. Conversely,rotation of central drive gear 192 a in the second direction causesrotation of each planetary gear 194 a in the first direction therebycausing rotation of rotatable support ring 196 in the second direction.The configuration of first planetary gear system 186 a provides areduction in the gear ratio. In this manner, the speed of rotation ofrotatable support ring 194 is less than the speed of rotation of centraldrive gear 190 a.

Second planetary gear system 186 b includes a central drive gear 192 bsecurely affixed to rotatable support ring 196 and a plurality ofplanetary gears 194 b rotatably mounted to a proximal end surface 188 aof screw member 188. Each planetary gear 194 b of second planetary gearsystem 186 b engages central drive gear 192 b and toothed inner surface185 of proximal housing section 182. As rotatable support ring 196 offirst planetary gear system 186 a rotates in the first direction therebycausing central drive gear 192 b to also rotate in the first direction,each planetary gear 174 b rotates in the second direction. As eachplanetary gear 194 b rotates in the second direction, engagement ofplanetary gears 194 b with toothed inner surface 185 of proximal housingsection 182 causes screw member 188 to rotate in the first direction.Conversely, rotation of central drive gear 192 b in the second directioncauses rotation of each planetary gear 194 b in the first direction,thereby causing screw member 198 to rotate in the second direction. Theconfiguration of second planetary gear system 186 b provides a reductionin the gear ratio. In this manner, the speed of rotation of screw member188 is less than the speed of rotation of central drive gear 182 b.First and second planetary gear systems 186 a, 186 b operate in unisonto provide a reduction in the gear ratio between second rotatableproximal drive shaft 118 and screw member 188. In this manner, thereduction in the speed of rotation of screw member 188 relative totubular connector 150 is a product of the reduction provided by thefirst and second planetary gear systems 186 a, 186 b.

Screw member 188 is rotatably supported within proximal housing portion182 and includes a threaded distal end 188 b that operably engages athreaded inner surface 190 a of pusher member 190. As screw member 188is rotated in the first direction, engagement of threaded distal end 188b of screw member 188 with threaded inner surface 190 a of pusher member190 (which is keyed to permit axial translation and prevent rotationthereof) causes longitudinal advancement of pusher member 190.Conversely, rotation of screw member 188 in the second direction causesretraction of pusher member 190.

Pusher member 190 of second pusher assembly 180 of adapter assembly 100includes a pair of tabs 198 formed on a distal end thereof for engagingconnector extensions 220, 224 (FIG. 18) of inner flexible band assembly220 (FIG. 18) of extension assembly 200 (FIG. 17). Although shown astabs 198, it is envisioned that pusher member 190 may include anystructure suitable for selectively engaging connector extensions 240,242 of outer flexible band 230 of extension assembly 200.

Turning now to FIGS. 17-34, extension assembly 200 for operablyconnecting adapter assembly 100 (FIG. 3) with a circular loading unit,e.g. loading unit 40 (FIG. 34) and an anvil assembly, e.g., anvilassembly 50 (FIG. 34) will be described. In particular, a proximal end202 of extension assembly 200 operably connects with distal end 104(FIG. 3) of adapter assembly 100 (FIG. 3) and a distal end 204 ofextension assembly 200 operably connects with loading unit 40 and anvilassembly 50. As shown, extension assembly 200 provides a slightcurvature between proximal and distal end 202, 204. In an alternativeembodiment, extension assembly 200 may be straight or may include agreater curvature. In accordance with the present disclosure, extensionassembly 200 may be substantially or fully rigid along its entirelength.

Although extension assembly 200 will be shown and described as beingused to connect loading unit 40 and anvil assembly 50 to adapterassembly 100 (FIG. 3), it is envisioned that the aspects of the presentdisclosure may be modified for use with various loading units, anvilassemblies, and adapter assemblies. Exemplary loading units and anvilassemblies are described in commonly owned U.S. Pat. No. 8,590,763, andU.S. patent application Ser. Nos. 14/056,301 and 14/149,355, thecontents of each being incorporated herein by reference in theirentirety.

Extension assembly 200 includes an inner flexible band assembly 210(FIG. 18), about an outer flexible band assembly 230 (FIG. 19) slidablydisposed about inner flexible band assembly 210, a frame assembly 250(FIG. 20) for supporting inner and outer flexible band assemblies 210,230, a trocar assembly 270 (FIG. 28) operably received through inner andouter flexible band assemblies 210, 230, and a connector assembly 290for securing loading unit 40 (FIG. 34) to extension assembly 200. Anouter sleeve 206 (FIG. 17) is received about frame assembly 250 andtrocar assembly 270, and inner and outer flexible band assemblies 210,230 are slideably received through outer sleeve 206. As will bedescribed in further detail below, extension assembly 200 may include adrive shaft 208 operably connected to trocar assembly 270 and extendingthrough proximal end 202 of extension assembly 200.

With reference to FIG. 18, inner flexible band assembly 210 includesfirst and second inner flexible bands 212, 214, a support ring 216, asupport base 218, and first and second connection extensions 220, 222.Proximal ends 212 a, 214 a of respective first and second inner flexiblebands 212, 214 are laterally spaced apart and securely attached tosupport ring 216. Distal ends 212 b, 214 b of first and second innerflexible bands 212, 214 are laterally spaced apart and securely attachedto a proximal end 218 a of support base 218. Each of first and secondinner flexible bands 212, 214 may be attached to support ring 216 and/orsupport base 218 in any suitable manner, including, for example, bypress-fitting, welding, adhesives, and/or with mechanical fasteners. Aswill be described in further detail below, inner flexible band assembly210 is configured to be slidably received about trocar assembly 270(FIG. 28) and within outer flexible band assembly 230 (FIG. 19) andouter sleeve 206 (FIG. 17).

First and second connection extensions 220, 222 of inner flexible bandassembly 210 extend proximally from support ring 216 and operablyconnect inner flexible band assembly 210 with pusher member 190 (FIG.15) of second pusher assembly 180 (FIG. 15) of adapter assembly 100(FIG. 3). In particular, each of first and second connection extensions220, 222 define respective openings 221, 223 configured to receive tabs198 (FIG. 15) of pusher member 190 (FIG. 15) of second pusher assembly180. Receipt of tabs 198 of pusher member 190 within openings 221, 223of respective first and second extensions 220, 222 secure inner flexibleband assembly 210 of extension assembly 200 with second pusher assembly180 of adapter assembly 100. First and second connection extensions 220,222 may be integrally formed with support ring 216, or attached theretoin any suitable manner.

Support base 218 extends distally from inner flexible bands 212, 214 andis configured to selectively connect extension assembly 200 with loadingunit 40 (FIG. 34). Specifically, a distal end 218 a of support base 218includes a flange 224 for operable engagement with an axially movableassembly (not shown) of loading unit 40 (FIG. 34). In one embodiment,flange 224 is configured for connection with a knife assembly (notshown) of loading unit 40 (FIG. 34).

With reference now to FIG. 19, outer flexible band assembly 230 issubstantially similar to inner flexible band assembly 210 and includesfirst and second flexible bands 232, 234 laterally spaced and connectedon proximal ends 232 a, 234 a to a support ring 236 and on distal ends234 b, 234 b to a proximal end 238 a of a support base 238. Each offirst and second outer flexible bands 232, 234 may be attached tosupport ring 236 and support base 238 in any suitable manner, including,for example, by press-fitting, welding, adhesives, and/or withmechanical fasteners. As will be described in further detail below,outer flexible band assembly 230 is configured to receive trocarassembly 270 (FIG. 28) therethrough.

First and second connection extensions 240, 242 of outer flexible bandassembly 230 extend proximally from support ring 236 and operablyconnect outer flexible band assembly 230 with pusher member 170 (FIG.12) of first pusher assembly 160 (FIG. 12) of adapter assembly 100 (FIG.1). In particular, each of first and second connection extensions 240,242 define respective openings 241, 243 configured to receive tabs 178(FIG. 12) of pusher member 170 of first pusher assembly 180. Receipt oftabs 178 of pusher member 170 within openings 241, 243 of respectivefirst and second extensions 240, 242 secures outer flexible bandassembly 230 of extension assembly 200 with first pusher assembly 180 ofadapter assembly 100. First and second connection extensions 240, 242may be integrally formed with support ring 236, or attached thereto inany suitable manner.

Support base 238 extends distally from outer flexible bands 232, 234 andis configured to selectively connect extension assembly 200 with loadingunit 40 (FIG. 34). Specifically, a distal end 238 b of support base 238includes a flange 244 for operable engagement with an axially movableassembly (not shown) of a loading unit (not shown). In one embodiment,flange 244 is configured for connection with a staple pusher assembly(not shown) of loading unit 40 (FIG. 34).

With reference now to FIGS. 20-26, frame assembly 250 includes first andsecond proximal spacer members 252, 254, and first and second distalspacer members 256, 258. When secured together, first and secondproximal spacer members 252, 254 define a pair of inner longitudinalslots 253 a for slidably receiving first and second flexible bands 212,214 (FIG. 18) of inner flexible band assembly 210 (FIG. 18) and a pairof outer longitudinal slots 253 b for slidably receiving first andsecond flexible bands 232, 234 (FIG. 19) of outer flexible band assembly230 (FIG. 19). First and second proximal spacer members 252, 254 furtherdefine a longitudinal passage 255 for receipt of trocar assembly 270.

In one embodiment, and as shown, first and second proximal spacermembers 252, 254 are formed of plastic and are secured together with asnap-fit arrangement. Alternatively, first and second proximal spacermembers 252, 254 may be formed of metal or other suitable material andmay be secured together in any suitable manner, including by welding,adhesives, and/or using mechanical fasteners.

First and second distal spacer members 256, 258 define a pair of innerslots 257 a for slidably receiving first and second flexible bands 212,214 (FIG. 18) of inner flexible band assembly 210 (FIG. 18) and a pairof outer slots 257 b for slidably receiving first and second flexiblebands 232, 234 (FIG. 19) of outer flexible band assembly 230 (FIG. 19).First and second distal spacer members 256, 258 further define alongitudinal passage 259 for receipt of trocar assembly 270.

In one embodiment, and as shown, each of first and second distal spacermembers 256, 258 are secured about inner and outer flexible bandassemblies 210, 230 and to outer sleeve 206 (FIG. 17) by a pair ofscrews 260 a, 260 b (FIG. 26). Alternatively, first and second distalspacer members 256, 258 may be secured together in any suitable manner,including by welding, adhesives, and/or using mechanical fasteners.First and second distal spacer members 256, 258 may be formed of metalor any other suitable material.

With reference now to FIGS. 27 and 28, frame assembly 250 furtherincludes a proximal seal member 262 and first and second distal sealmembers 264, 266. Each of proximal seal member 252 and first and seconddistal seal members 264, 266 include seals halves 262 a, 262 b, 264 a,264 b, 266 a, 266 b, respectively. Proximal seal member 262 is receivedbetween first and second proximal spacer members 252, 254 and first andsecond distal spacer members 256, 258. First half 264 a of first distalseal member 264 is secured to first half 266 a of second distal sealmember 266 and second half 264 b of first distal seal member 264 issecured to second half of second distal seal member 266. Proximal sealmember 262 and first and second distal seal members 264, 266 engageouter sleeve 206 (FIG. 17), inner and outer flexible bands 212, 214 and232, 234 of respective inner and outer flexible band assemblies 210, 230and trocar assembly 270 (FIG. 28) in a sealing manner. In this manner,proximal seal member 262 and first and second distal seal members 264,266 operate to provide a fluid tight seal between distal end 204 andproximal end 202 of extension assembly 200.

With reference to FIGS. 29-32, trocar assembly 270 of extension assembly200 includes an outer housing 272, a trocar member 274 slidably disposedwithin tubular outer housing 272, and a drive screw 276 operablyreceived within trocar member 274 for axially moving trocar member 274relative to tubular housing 272. In particular, trocar member 274includes a proximal end 274 a having an inner threaded portion 275 whichengages a threaded distal portion 276 b of drive screw 276. As drivescrew 276 is rotated within trocar member 274, engagement of innerthreaded portion 275 of trocar member 274 with threaded distal portion276 b of drive screw 276 causes longitudinal movement of trocar member274 within outer housing 272 of trocar assembly 270. Rotation of drivescrew 276 in a first direction causes longitudinal advancement of trocarmember 274 and rotation of drive screw 276 in a second direction causeslongitudinal retraction of trocar member 274. A distal end 274 b oftrocar member 274 is configured to selectively engage anvil assembly 50(FIG. 34).

A bearing assembly 278 is mounted to a proximal end 272 a of outerhousing 272 of trocar assembly 270 for rotatably supporting a proximalend 276 a of drive screw 276 relative to outer housing 272 and trocarmember 274. Bearing assembly 278 includes a housing 280, proximal anddistal spacers 282 a, 282 b, proximal and distal retention clips 284 a,284 b, proximal and distal bearings 286 a, 286 b, and a washer 288. Asshown, proximal end 276 a of drive screw 276 includes a flange 276 c forconnection with a link assembly 277. A distal portion 277 b of linkassembly 277 is pivotally received between first and second proximalspacer members 252, 254 and operably engages flange 276 c on drive screw276. A proximal end 277 a of link assembly 277 is configured foroperable engagement with a distal end 208 b of drive shaft 208.

With reference now to FIGS. 32 and 33, connector assembly 290 ofextension assembly 200 includes a tubular connector 292 attached to adistal end 206 a of outer sleeve 206 and about distal ends of inner andouter flexible assemblies 210, 230 (FIG. 26) and trocar assembly 270. Inparticular, a proximal end 292 a of tubular connector 292 is receivedwithin and securely attached to distal end 206 b of outer sleeve 206 bya retaining clip 294. An O-ring 296 forms a fluid tight seal betweentubular connector 292 of connector assembly 290 and outer sleeve 206. Adistal end 292 b of tubular connector 292 is configured to selectivelyengage a proximal end of loading unit 40 (FIG. 34). Distal end 292 b oftubular connector 292 engages the circular loading unit with a snap-fitarrangement, bayonet coupling, or in another suitable manner.

With reference now to FIGS. 34 and 35, extension assembly 200 isconnected to adapter assembly 100 by receiving proximal end 202 (FIG.17) of extension assembly 200 within distal end 104 of adapter assembly100. In particular, first and second connection extensions 220, 240,222, 242 of respective inner and outer flexible band assemblies 210, 230are received within sleeve 106 of adapter assembly 100 such that tabs178 of pusher member 170 of first pusher assembly 160 of adapterassembly 100 are received within openings 241, 243 of respective firstand second connection extensions 240, 242 of outer flexible bandassembly 230 to secure outer flexible band assembly 230 with firstpusher assembly 160 and tabs 198 of pusher member 190 of second pusherassembly 180 of adapter assembly 100 are received within openings 221,223 of first and second connection extensions 221, 223 of inner flexibleband assembly 210 to secure inner flexible band assembly 210 with secondpusher assembly 180.

As noted above, adapter assembly 100 may include a drive shaft 108 (FIG.3) that extends from distal end 104 of adapter assembly 100.Alternatively, extension assembly 200 may include a drive shaft 208extending from proximal portion 202 of extension assembly 200. In theevent both adapter assembly 100 includes drive shaft 108 and extensionassembly 200 includes drive shaft 208, prior to receipt of proximalportion 202 of extension assembly 200 within distal end 104 of extensionassembly 100, one of drive shaft 108, 208 must be removed fromrespective adapter assembly 100 and extension assembly 200. Duringreceipt of proximal portion 202 of extension assembly 200 within distalend 102 of adapter assembly 100, either distal end 108 b (FIG. 35) ofdrive shaft 108 b (FIG. 35) engages proximal portion 277 b (FIG. 35) oflink assembly 277, or proximal end 208 a (FIG. 17) of drive shaft 208(FIG. 17) is received within socket 145 of drive member 140 of drivetransfer assembly 130 of extension assembly 100 (FIG. 12).

After extension assembly 200 is operably engaged with adapter assembly100, and adapter assembly 100 is operably engaged with surgical device10 (FIG. 1), loading unit 40 (FIG. 34) of end effector 30 (FIG. 34) maybe attached to connector assembly 290 of extension assembly 200 and ananvil assembly 50 (FIG. 34) may be attached to distal end 274 b oftrocar 274 of extension assembly 200 in a conventional manner. Duringactuation of loading unit 40 and anvil assembly 50, longitudinaladvancement of pusher member 190 of second pusher assembly 180 ofadapter assembly 100, as described above, and as indicated by arrows “C”in FIG. 35, causes longitudinal advancement of outer flexible bandassembly 230 of extension assembly 200 and longitudinal advancement ofpusher member 170 of first pusher assembly 160, as described above, andas indicated by arrows “D” in FIG. 35, causes longitudinal advancementof inner flexible band assembly 210. Rotation of drive shaft 108 in afirst direction, as described above, and as indicated by arrow “E”,causes advancement of trocar 274 of extension assembly 200. Conversely,longitudinal retraction of pusher member 190 causes longitudinalretraction of outer flexible band assembly 230, longitudinal retractionof pusher member 170 causes longitudinal retraction of inner flexibleband assembly 210, and rotation of drive shaft 108 in a second directioncauses retraction of trocar 274 of extension assembly 200.

In one embodiment, inner flexible band assembly 210 is operablyconnected to a knife assembly (not show) of loading unit 40 (FIG. 34) ofend effector 30 (FIG. 34) attached to connection assembly 290 ofextension assembly 200, outer flexible band assembly 230 is operablyconnected to a staple driver assembly (not shown) of loading unit 40,and trocar 274 is operably connected to anvil assembly 50 (FIG. 34) ofend effector 30 (FIG. 34). In this manner, longitudinal movement ofinner flexible band assembly 210 causes longitudinal movement of theknife assembly, longitudinal movement of outer flexible band assembly230 causes longitudinal movement of the staple driver assembly, andlongitudinal movement of trocar 274 causes longitudinal movement ofanvil assembly 50 relative to loading unit 40.

With reference to FIGS. 36-41, an adapter assembly according to anotherembodiment of the present disclosure is shown as adapter assembly 300.Adapter assembly 300 is substantially similar to adapter assembly 100described hereinabove and will only be described as it relates to thedifferences therebetween.

As will become apparent from the following description, theconfiguration of adapter assembly 300 permits rotation of a distalportion 304 of adapter assembly 300 about a longitudinal axis “X” (FIG.37), relative to a proximal portion 302 of adapter assembly 300. In thismanner, an end effector, e.g. end effector 30 (FIG. 34) secured todistal portion 304 of adapter assembly 300 or an end effector secured toan extension assembly, e.g., extension assembly 200 (FIG. 17) which issecured to distal portion 304 of adapter assembly 300 is rotatable aboutlongitudinal axis “X” independent of movement of the surgical device(not shown) to which adapter assembly 300 is attached.

Adapter assembly 300 includes a base 306 and a support structure 308rotatable relative to base 306 along longitudinal axis “X” of adapterassembly 300. A rotation handle 310 is rotatably secured to base 306 andfixedly secured to a proximal end of support structure 308. Rotationhandle 310 permits longitudinal rotation of distal portion 304 ofadapter assembly 300 relative to proximal end 302 of adapter assembly300. As will be described in further detail below, a latch 312 ismounted to rotation handle 310 and selectively secures rotation handle310 in a fixed longitudinal position.

Proximal portion 302 of adapter assembly 300 includes a drive couplingassembly 320 and a drive transfer assembly 330 operably connected todrive coupling assembly 320. Distal portion 304 of adapter assembly 300includes a first pusher assembly 340 operably connected to drivetransfer assembly 330, and a second pusher assembly 350 operablyconnected to drive transfer assembly 330. Drive coupling assembly 320and drive transfer assembly 330 are mounted within base 306, and thus,remain rotationally fixed relative to the surgical device (not shown) towhich adapter assembly 300 is attached. First pusher assembly 340 andsecond pusher assembly 350 are mounted within support structure 308, andthus, are rotatable relative to the surgical device (not shown) to whichadapter assembly 300 is attached.

Drive coupling assembly 320 is configured to selectively secure adapterassembly 300 to a surgical device (not shown). For a detaileddescription of an exemplary surgical device and drive coupling assembly,please refer to commonly owned U.S. Provisional Patent Application Ser.No. 61/913,572, filed Dec. 9, 2013, the content of which is incorporatedby reference herein in its entirety.

Rotation knob 310 is rotatably secured to base 306. Latch 312 includes apin 312 a (FIG. 40) configured to lock rotation knob 310 relative tobase 306. In particular, pin 312 a of latch 312 is received within aslot 307 formed in base 306 and is biased distally by a spring 314 intoa notch 307 a (FIG. 40) formed in base 306 and in communication withslot 307 to lock rotation knob 310 relative to base 306. Proximalmovement of latch 312, as indicated by arrow “F” in FIG. 36, retractspin 312 a from within notch 307 a to permit rotation of rotation knob310 relative to base 306. Although not shown, it is envisioned that base306 may define a number of notches radially spaced about base 306 and incommunication with slot 307 that permit rotation knob 310 to be lockedin a number of longitudinal orientations relative to base 306.

Drive transfer assembly 330, first drive pusher assembly 340, and seconddrive pusher assembly 350 of adapter assembly 300 are substantiallyidentical to respective drive transfer assembly 130, first drive pusherassembly 160, and second drive pusher assembly 180 of adapter assembly100 described hereinabove, and therefore, will only be described asrelates to the differences therebetween.

Support structure 308 is fixedly received about first and second drivepusher assemblies 340, 350 and rotatably relative to base 306. As notedabove, rotation knob 310 is fixedly secured to the proximal end ofsupport structure 308 to facilitate rotation of support structure 308relative to base 306. Support structure 308 is retained with outersleeve 305 of adapter assembly 300 and is configured to maintain axialalignment of first and second drive pusher assemblies 340, 350. Supportstructure 308 may also reduce the cost of adapter assembly 300 whencompared to the cost of adapter assembly 100.

Support structure 308 respectively includes first, second, third,fourth, fifth, sixth, and seventh plates 360 a, 360 b, 360 c, 360 d, 360e, 360 f, 360 g, a first and a second plurality of tubular supports 362a, 362 b, first and second support rings 364 a, 364 b, a first and asecond plurality of ribs 366 a, 366 b, and a plurality of rivets 368.From proximal to distal, first and second plates 360 a, 360 b aremaintained in spaced apart relation to each other by the first pluralityof tubular supports 362 a, second and third plates 360 b, 360 c aremaintained in spaced apart relation to each other by first support ring364 a, third and fourth plates 360 c, 360 d are maintained in spacedapart relation to each other by the first plurality of support ribs 366a, fourth and fifth plates 360 d, 360 e are maintained in spaced apartrelation to each other by the second plurality of tubular supports 362b, fifth and sixth plates 360 e, 360 f are maintained in spaced apartrelation to each other by second support ring 364 b, and sixth andseventh plates 360 f, 360 g are maintained in spaced apart relation toeach other by the second plurality of support ribs 366 b. First, second,third, fourth, fifth, sixth, and seventh plates 360 a-g are heldtogether by a plurality of rivets 368 secured to first and seventhplates 360 a, 360 g and extending through second, third, fourth, fifth,and sixth plates 360 b-360 f, first and second support rings 364 a, 364b, and respective first and second plurality of tubular support 362 a,362 b.

Adapter assembly 300 operates in a substantially similar manner toadapter assembly 100 described hereinabove. In addition, as described indetail above, adapter assembly 300 is configured to permit rotation ofan end effector, e.g., end effector 30 (FIG. 34) attached to adapterassembly 300 or attached to an extension assembly that is attached toadapter assembly 300 to be selectively rotated about longitudinal axis“X” (FIG. 37) during use.

With reference now to FIGS. 42-44, an adapter assembly according toanother embodiment of the present disclosure is shown generally asadapter assembly 400. Adapter assembly 400 is substantially similar toadapter assemblies 100 and 300 described hereinabove, and therefore willonly be described as relates to the differences therebetween.

Adapter assembly 400 includes a proximal portion 402 and a distalportion 404 rotatable along a longitudinal axis “X” relative to proximalportion 402. Distal portion 404 includes a support structure 408 securedto outer sleeve 405 and formed about first and second pusher assemblies440, 450. Support structure 408 includes a plurality of reinforcingmembers 462 extending substantially the length of outer sleeve 405.Reinforcing members 462 each include a proximal tab 462 a and a distaltab 462 b which extend through outer sleeve 405 to secure reinforcingmember 462 within outer sleeve 405. Proximal tabs 462 of reinforcingmembers 462 are further configured to engage a rotation knob 410 ofadapter assembly 400. Adapter assembly 400 may include annular plates(not shown) positioned radially inward of reinforcing members 462 thatmaintain proximal and distal tabs 462 a, 462 b of reinforcing members462 in engagement with outer sleeve 405. The annular plates may alsoprovide structure support to distal portion 404 of adapter assembly 400.

With reference to FIGS. 45-49, a connection assembly according to anembodiment of the present disclosure is shown generally as connectionassembly 500. As shown and will be described, connection assembly 500 isconfigured to be attached to first and second tubular bodies (not shown)for connecting the first tubular body, i.e., adapter assembly 100 (FIG.3), 300 (FIG. 36), 400 (FIG. 42), to the second tubular body, i.e.,extension assembly 200 (FIG. 17). It is envisioned, however, that theaspects of the present disclosure may be incorporated directly into thefirst and second tubular bodies to permit connection of the firsttubular body directly to the second tubular body.

Connection assembly 500 includes a tubular base 510 and a tubularextension 520 formed of first and second sections 520 a, 520 b and anouter sleeve 522. As shown, tubular base 510 defines a pair of openings511 for securing tubular base 510 to a first tubular body (not shown).Alternatively, tubular base 510 may include only a single opening, oneor more tabs (not shown), and/or one or more slots (not shown), forsecuring tubular base 510 to the first tubular body (not shown). Aflange 512 extends from a first end of tubular base 510 and includes anannular rim 514 extending thereabout.

First and second sections 520 a, 520 b of tubular extension 520 aresubstantially similar to one another and each define an annular groove521 formed along an inner first surface thereof. Each of first andsecond section 520 a, 520 b of tubular extension 520 is configured to bereceived about flange 512 of tubular base 510 such that rim 514 oftubular base 510 is received within grooves 521 of first and secondsections 520 a, 520 b of tubular extension 520. Once first and secondsections 520 a, 520 b of tubular extension 520 are received about flange512 of tubular base 510, outer sleeve 522 of tubular extension 520 isreceived about first and second sections 520 a, 520 b of tubularextension 520 to secure tubular extension 520 to tubular base 510.

As shown, each of first and second sections 520 a, 520 b of tubularextension 520 define an opening 523 configured to be aligned with a pairof openings 525 in outer sleeve 522 to secure outer sleeve 522 to firstand second sections 520 a, 520 b. Either or both of first and secondsections 520 a, 520 b and outer sleeve 522 may include one or more tabs,and/or one or more slots for securing outer sleeve 522 about first andsecond extensions. Alternatively, outer sleeve 522 may be secured tofirst and second sections 520 a, 520 b in any suitable manner.

Outer sleeve 522 may be selectively secured about first and secondextensions for selective removal of outer sleeve 522 from about firstand second sections 520 a, 520 b to permit separation of tubularextension 520 from tubular base 510. Alternatively, outer sleeve 522 maybe permanently secured about first and second sections 520 a, 520 b toprevent tubular extension 520 from being separated from tubular base510. As noted above, although tubular base 510 and tubular extension 520are shown and described as forming an independent connection assembly500, it is envisioned that tubular base 510 may be formed on a firsttubular member, i.e., adapter assembly 100 (FIG. 3) and tubularextension 520 may be formed on a second tubular member, i.e., extensionassembly 200 (FIG. 17) such that the first tubular member may bedirectly connected to the second tubular member.

With reference to FIGS. 50-52, an alternate embodiment of a trocarassembly 1270 is shown in combination with an alternate embodiment of anextension assembly 1200. Trocar assembly 1270 is similar to trocarassembly 270 described above, and not all similarities will be discussedherein. However, while trocar assembly 270 is configured for secureengagement to link assembly 277 of extension assembly 200, trocarassembly 1270 is configured for releasable engagement with extensionassembly 1200.

With particular reference to FIG. 50, trocar assembly 1270 includes apair of flattened portions 1280 about its perimeter, and extensionassembly 1200 includes a pair of openings 1210 a, 1210 b through itsouter wall or sleeve 1206 (opening 1210 a is not visible in FIG. 50).When trocar assembly 1270 is engaged with extension assembly 1200,flattened portions 1280 of trocar assembly 1270 are axially aligned withopenings 1210 a, 1210 b of extension assembly 1200. In this position, apair of retention members 1300 a, 1300 b is insertable throughrespective openings 1210 a, 1210 b and adjacent (e.g., in contact with)flattened portions 1280.

More particularly, each retention member 1300 a, 1300 b includes anextension portion 1310 a, 1310 b and a receptacle 1320 a, 1320 b,respectively. Each extension portion 1310 a, 1310 b is configured toreleasably engage receptacle 1320 a, 1320 b of the opposite retentionmember 1300 a, 1300 b. That is, extension portion 1310 a of retentionmember 1300 a is configured to releasably engage receptacle 1320 b ofretention member 1300 b; extension portion 1310 b of retention member1300 b is configured to releasably engage receptacle 1320 a of retentionmember 1300 a. It is envisioned that extension portions 1310 a, 1310 brespectively engage receptacles 1320 b, 1320 a via a snap-fitconnection. It is further envisioned that retention member 1300 a isidentical to retention member 1300 b, which may be helpful to minimizemanufacturing costs and to facilitate assembly.

In use, to engage trocar assembly 1270 with extension assembly 1200,trocar assembly 1270 is inserted through a distal opening 1202 ofextension assembly 1200 until a proximal end 1276 a of a drive screw1276 of trocar assembly 1200 engages a link assembly of trocar assembly1200 (see link assembly 277 of trocar assembly 270 in FIG. 32, forexample). Next, extension portion 1310 a, 1310 b of each retentionmember 1300 a, 1300 b, respectively, is inserted through respectiveopening 1210 a, 1210 b of outer sleeve 1206, across flattened portion1280 of trocar assembly 1270 and into receptacle 1320 b, 1320 a of theother retention member 1300 b, 1300 a, respectively. That is, extensionportion 1310 a of retention member 1300 a is inserted through opening1210 a (or 1210 b) of outer sleeve 1206, across flattened portion 1280and into receptacle 1320 b of retention member 1300 b, and extensionportion 1310 b of retention member 1300 b is inserted through opening1210 b (or 1210 a) of outer sleeve 1206, across flattened portion 1280and into receptacle 1320 a of retention member 1300 a. The engagementbetween extension portion 1310 a, flattened portion 1280 and receptacle1320 b, and the engagement between extension portion 1310 b, flattenedportion 1280 and receptacle 1320 a is configured to prevent longitudinaltranslation of a trocar member 1274 of trocar assembly 1270 with respectto outer sleeve 1206 of trocar assembly 1200 (e.g., due to theengagement between extension portions 1310 a, 1310 b and walls 1282 offlattened portion 1280). Additionally, the engagement between extensionportion 1310 a, flattened portion 1280 and receptacle 1320 b, and theengagement between extension portion 1310 b, flattened portion 1280 andreceptacle 1320 a is configured to prevent relative rotation betweentrocar member 1274 of trocar assembly 1270 and outer sleeve 1206 oftrocar assembly 1200.

Additionally, and with particular reference to FIG. 50, each retentionmember 1300 a, 1300 b includes a nub 1302 (only nub 1302 associated withretention member 1300 a is shown), which is configured to mechanicallyengage a detent 1284 of trocar assembly 1270. It is envisioned that theengagement between nubs 1302 and detents 1284 helps maintain the properalignment and/or orientation between retention members 1300 a, 1300 band trocar assembly 1270.

To disengage retention members 1300 a, 1300 b from each other, it isenvisioned that a user can use a tool (e.g., a screwdriver-type tool) topush extension portions 1310 a, 1310 b out of receptacles 1320 b, 1320a, respectively. It is also envisioned that retention members 1300 a,1300 b are configured to be tool-lessly disengaged from each other andfrom trocar assembly 1270. Disengagement of retention members 1300 a,1300 b allows trocar assembly 1270 to be removed from outer sleeve 1206of trocar assembly 1200 (e.g., for replacement or cleaning). It isenvisioned that cleaning can occur by inserting a cleaning device atleast partially within at least one opening 1210 a, 1210 b of outersleeve 1206 of extension assembly 1200, and directing a cleaning fluid(e.g., saline) proximally and/or distally to help flush out anycontaminants that may be present within outer sleeve 1206, for example.

Additionally, while extension assembly 1200 and trocar assembly 1270 areshown used in connection with adapter assembly 100, the presentdisclosure also envisions the use of extension assembly 1200 and/ortrocar assembly 1270 with a surgical instrument (e.g., a circularstapling instrument) without the use of an adapter assembly.

With reference to FIGS. 53-55, the present disclosure also includes astrain gauge 1500, a position sensor 1520, and a memory sensor 1540(e.g., an E-PROM (erasable programmable read-only memory) sensor). Withparticular reference to FIG. 55, it is envisioned that a flexible cable1600 extends between strain gauge 1500, position sensor 1520, memorysensor 1540 and a printed circuit board (not shown), and from theprinted circuit board to an electrical connector disposed at proximalportion 302 of adapter assembly 300, for example.

It is envisioned that strain gauge 1500 is used to detect an axial loadexerted on the tissue during clamping of tissue. Here, it is envisionedthat if this load is too great, or exceeds a predetermined value, theuser (or stapling device 10 itself) may abort the stapling operation ormay choose to use a different stapling device 10 or adapter assembly100, for example.

It is envisioned that position sensor 1520 is used to detect the axialposition of the fasteners during the stapling process (e.g., when thefasteners are being ejected from adapter assembly 100). It is furtherenvisioned that memory sensor 1540 is configured to recognize the sizeand/or type of staple cartridge that is engaged with adapter assembly100 that is engaged with stapling device 10 and to relay thisinformation to handle housing 12 of stapling device 10.

Any of the components described herein may be fabricated from eithermetals, plastics, resins, composites or the like taking intoconsideration strength, durability, wearability, weight, resistance tocorrosion, ease of manufacturing, cost of manufacturing, and the like.

Persons skilled in the art will understand that the devices and methodsspecifically described herein and illustrated in the accompanyingdrawings are non-limiting exemplary embodiments. It is envisioned thatthe elements and features illustrated or described in connection withone exemplary embodiment may be combined with the elements and featuresof another without departing from the scope of the present disclosure.As well, one skilled in the art will appreciate further features andadvantages of the disclosure based on the above-described embodiments.Accordingly, the disclosure is not to be limited by what has beenparticularly shown and described, except as indicated by the appendedclaims.

What is claimed is:
 1. An adapter assembly for operably connecting anend effector to a surgical instrument, the adapter assembly comprising:a first proximal shaft including a first gear assembly; a secondproximal shaft defining a longitudinal axis and including a second gearassembly; a first distal shaft disposed along the longitudinal axis andincluding a third gear assembly, the first gear assembly beingmechanically engaged with the third gear assembly such that rotation ofthe first gear assembly causes rotation of the third gear assembly; anda second distal shaft including a fourth gear assembly, the second gearassembly being mechanically engaged with the fourth gear assembly suchthat rotation of the second gear assembly causes rotation of the fourthgear assembly, a distal portion of the second distal shaft is disposedat least partially within an internal cavity of the third gear assembly.2. The adapter assembly according to claim 1, wherein the second distalshaft is rotatable about the longitudinal axis with respect to the thirdgear assembly.
 3. The adapter assembly according to claim 1, whereineach of the first gear assembly, the second gear assembly, the thirdgear assembly, and the fourth gear assembly is disposed within ahousing.
 4. The adapter assembly according to claim 3, furthercomprising a support plate disposed within the housing, the supportplate being rotationally fixed with respect to the housing.
 5. Theadapter assembly according to claim 4, wherein the support plateincludes at least one aperture extending therethrough.
 6. The adapterassembly according to claim 5, wherein a first aperture of the at leastone aperture of the support plate is disposed about the longitudinalaxis and is axially aligned with a portion of the second distal shaft.7. The adapter assembly according to claim 6, wherein the first apertureis axially aligned with a portion of the third gear assembly.
 8. Theadapter assembly according to claim 4, wherein the second gear assemblyincludes a plurality of gear teeth disposed proximally of the supportplate.
 9. The adapter assembly according to claim 8, wherein the thirdgear assembly includes a plurality of gear teeth disposed distally ofthe support plate.
 10. The adapter assembly according to claim 9,wherein a portion of the first proximal shaft extends through a secondaperture of the at least one aperture of the support plate.
 11. Theadapter assembly according to claim 10, wherein a portion of the seconddistal shaft extends through a third aperture of the at least oneaperture of the support plate.
 12. The adapter assembly according toclaim 6, wherein the portion of the second distal shaft that is axiallyaligned with the first aperture of the support plate includes a diameterthat is slightly smaller than a diameter of the first aperture such thatthe second distal shaft is rotatable with respect to the support plateand such that the support plate supports the second distal shaft. 13.The adapter assembly according to claim 1, further comprising a firstassembly operably connected to the first distal shaft for convertingrotational motion from the first distal shaft to longitudinal movementto perform a first function.
 14. The adapter assembly according to claim13, further comprising a second assembly operably connected to thesecond distal shaft for converting rotational motion from the seconddistal shaft to longitudinal movement to perform a second function. 15.The adapter assembly according to claim 13, wherein the first functionincludes axially moving a trocar member with respect to the first distalshaft.
 16. The adapter assembly according to claim 14, wherein thesecond function includes axially moving an anvil with respect to thesecond distal shaft.
 17. A surgical instrument, comprising: a firstproximal shaft disposed in mechanical cooperation with a first gearassembly; a second proximal shaft defining a longitudinal axis and beingdisposed in mechanical cooperation with a second gear assembly, thesecond gear assembly being rotatable about the longitudinal axis withrespect to the first proximal shaft; a first distal shaft disposed alongthe longitudinal axis and being disposed in mechanical cooperation witha third gear assembly, the third gear assembly being rotatable about thelongitudinal axis with respect to the first proximal shaft, the firstgear assembly being mechanically engaged with the third gear assemblysuch that rotation of the first gear assembly causes rotation of thethird gear assembly; and a second distal shaft including a fourth gearassembly, the second gear assembly being disposed in mechanicalcooperation with the fourth gear assembly such that rotation of thesecond gear assembly causes rotation of the fourth gear assembly, adistal portion of the second distal shaft being disposed at leastpartially within an internal cavity of the third gear assembly.
 18. Thesurgical instrument according to claim 17, wherein the second proximalshaft is rotatable with respect to the third gear assembly.
 19. Thesurgical instrument according to claim 17, further comprising a firstassembly operably connected to the first distal shaft for convertingrotational motion from the first distal shaft to axially move a trocarmember with respect to the first distal shaft.
 20. The surgicalinstrument according to claim 19, further comprising second assemblyoperably connected to the second distal shaft for converting rotationalmotion from the second distal shaft axially move an anvil with respectto the second distal shaft.